16 FRESH-WATER COOLING 2002, 2003 1 2 10. 12 3. Fit the circulation pump (complete with tensioner bracket and spacer sleeve, position 4). Tighten the bolts (M8x75) to 20 Nm (2,0 kp) (14.7 ft.lbs), position 1. Suspend the heat exchanger loosely by the rear bolt (M8x16 and spring washer), position 5. a) Fit the pipe (position 6) and the hose (position 3) between the heat exchanger and the sea-water pump, using double hose clamps (apply soapy water to the rubber rings, applies for all rubber rings). ) Fit the pipe between the heat-exchanger and thermostat housing, position 7. ©) Fit the pipe between the heat-exchanger and the circulation pump, position 8. Locate the pipes in the heat-exchanger and and draw it forward tightening it with the two bolts (M&x16 and spring washers), positions 5 and 9. Fit the pipe between the heat-exchanger and the exhaust elbaw, position 10. NOTE! The holder for the pipe, (position 11) and the lock (position 112). Fit the pipe between the circulation pump (lower outlet) and the cylinder head, position 12. Fit the pipe between the circulation pump (upper outlet) and the cylinder head, position 13, Fit the alternator, place the bolt for the tensioner bracket with the head forwards. Put on and tension the V-belt. Fit the expansion tank to the exhaust elbow, position 15. Fitthe hose between the tank and the circulation pump (double pipe ) 2002 = 450 mm (17.7 in), 2003 = 550 mm (21.7 in) (only single hose clamps are used on the fresh-water system), position 16. Fit the nipple, position 17. Fitthe hose between the tank and the thermostat housing (nipple 17) : 200: in), position 18. Fit the plugs in the exhaust elbow and the cylinder head, positions 19 and 20. Fill the system to the right level with a mixture of fresh water (50 %) and anti-freeze (50 %), alternatively rust-pro- tection additive (VP accessory). The fresh-water system volumes: 2002 = 4.0 dm? (litre) (0.88 Imp. gals) (1.1 US gals), 2003 = 5.5 dm? (litre) (1.2 Imp. gals) (1.45 US gals). 350mm (13.8 in), 2003 = 450 mm (17.7 Pos 21 and 23 are for hot water outlet.